An Apex ReclaimX™ WT Wastewater Reuse Project Delivers 20 Million Gallons of Reclaimed Water and $188,000 in Annual Water and Sewer Savings.
Executive Summary
A leading global dairy manufacturer engaged Apex Water & Process to implement a wastewater reuse strategy at its Mid-Atlantic dairy plant. Using the ReclaimX™ WT platform, the facility converts treated wastewater into high-quality cooling tower makeup water through advanced oxidation, ultrafiltration, reverse osmosis, and automated cleaning technologies. Today, the system reclaims approximately 20 million gallons of water annually, reducing municipal water consumption by about 30 million gallons each year, lowering operating costs, and advancing the company’s sustainability and water stewardship goals.
Results at a Glance
- Approximately 20 million gallons of water reused each year
- About 30 million gallons of city water saved each year
- About $188,000 in annual water and sewer savings
- Low-TDS makeup water leading to 25% bleed reduction
- Reduced groundwater withdrawal and municipal water demand
- Supports corporate sustainability and water stewardship initiatives
Customer Overview
A leading global dairy manufacturer sought to implement a wastewater reuse strategy that would reduce freshwater demand, lower water and sewer costs, and support corporate sustainability goals at its Mid-Atlantic alternative milk and creamer production facility.
The plant generated a substantial volume of treated wastewater through its onsite wastewater treatment system. Rather than sending all treated effluent to discharge, plant leadership recognized an opportunity to recover and reuse water for cooling tower operations, reducing dependence on municipal water supplies while improving overall water efficiency.
To achieve these objectives, the manufacturer engaged Apex to optimize and operationalize a working wastewater reclamation solution with the ReclaimX™ platform.
The Challenge
The facility operated a sophisticated wastewater treatment system consisting of:
- Equalization
- Primary clarification
- Aerobic digestion
- Anoxic digestion
- Secondary clarification
The system consistently produced compliant effluent with low biological oxygen demand (BOD), total suspended solids (TSS), and nitrogen concentrations. However, producing reliable reverse osmosis (RO) permeate from wastewater effluent presented a unique challenge.
Unlike municipal water treatment, wastewater reclaim systems must accommodate constantly changing wastewater characteristics driven by:
- Production variability
- Cleaning-in-place (CIP) cycles
- Biological treatment performance
- Seasonal operating conditions
- Coagulants and polymer treatment programs
The facility had previously explored wastewater reclaim opportunities but needed a more robust solution capable of reliably producing cooling tower makeup water while minimizing operator intervention and membrane fouling.
The Solution
Following several months of pilot testing and evaluation of previous reclaim failures, Apex implemented a ReclaimX™ WT wastewater reuse platform that is optimized specifically for dairy wastewater applications.
The solution included:
Advanced Oxidation Pretreatment
Electrocoagulation-based advanced oxidation stabilized wastewater quality, reduced biological fouling potential, and eliminated the need for significant chemical pretreatment.
Submerged Ultrafiltration (UF)
Unlike conventional pressure ultrafiltration systems, submerged UF membranes provided superior resistance to solids fluctuations and wastewater variability while maintaining stable performance.
Reverse Osmosis (RO)
A specialized RO system removed dissolved minerals, salts, and residual contaminants to produce high-quality reclaimed water suitable for cooling tower makeup applications.
Chemically Enhanced Automated Flushing (CEAF)
ReclaimX™ incorporates Chemically Enhanced Automated Flushing (CEAF), a proprietary approach that helps control membrane fouling, extend cleaning intervals, reduce downtime, and improve overall system reliability.
Real-Time Monitoring and Optimization
Advanced controls, monitoring systems, and ongoing optimization support help operators maintain consistent water quality while minimizing labor requirements.
Pilot Testing Validated Performance
During pilot testing, the wastewater treatment system experienced a significant clarifier upset that increased total suspended solids concentrations from approximately 100 ppm to 500 ppm.
Despite the upset conditions, the ReclaimX™ WT treatment train maintained stable membrane performance and continued producing reusable water, demonstrating the system’s ability to handle real-world dairy wastewater fluctuations.
This pilot validation gave the customer confidence that the solution could operate reliably under changing process conditions.
Optimization for Long-Term Success
Wastewater reuse projects require more than installation; they require continuous optimization. During startup and operation, Apex worked closely with facility personnel to optimize:
- Ultrafiltration chemically enhanced backwash (CEB) procedures
- Polymer feed rates within the wastewater treatment process
- Membrane operating conditions
- Reverse osmosis cleaning strategies
- CEAF operating protocols
As operating conditions evolved, Apex refined membrane cleaning procedures and flush protocols to reduce fouling and extend cleaning intervals. Through this optimization effort, the facility was able to improve uptime, reduce chemical consumption, and maximize reclaimed water production.
Results: Industrial Water Recycling Success
Water Conservation
The ReclaimX™ WT system now produces approximately 20 million gallons of reclaimed water annually for cooling tower makeup. By replacing municipal water with reclaimed RO permeate, the facility has significantly reduced freshwater consumption while improving cooling system performance through the use of low-TDS makeup water.
Cost Savings
The ReclaimX™ system generates approximately $188,000 in annual water and sewer savings by reducing municipal water consumption and wastewater discharge costs.
Improved Cooling Tower Performance
The high-quality RO permeate provides:
- Lower dissolved solids concentrations
- Improved cooling tower efficiency
- Reduced blowdown requirements
- Lower scaling potential
- More consistent cooling water quality
| Digester Effluent | ReclaimX Treated | |
| T. Hardness (mg/L as CaCO3) | 116 | 2.5 |
| Conductivity (µmho) | 1,983 | 30 |
| Chloride (mg/L) | 81 | 2 |
| Sodium (mg/L) | 454 | 9 |
| Phosphate (mg/L) | 32 | 0.5 |
| Silica (mg/L) | 12 | 1.0 |
| Sulfate (mg/L) | 120 | 8 |
| COD (mg/L) | 125 | <1.0 |
| TSS (mg/L) | 45 | <0.1 |
| pH | 7.9 | 6.7 |
Sustainability Impact
The project delivers measurable environmental benefits, including:
- Approximately 30 million gallons of city water conserved annually
- Reduced stress on local groundwater resources
- Reduced municipal water demand
- Advancement of corporate sustainability goals
- Improved water stewardship performance
Customer Impact
By transforming treated wastewater into a reliable source of utility water, the facility converted wastewater from a disposal cost into a valuable operational asset.
Today, the ReclaimX™ WT system helps the manufacturer:
- Reduce freshwater consumption
- Lower operating costs
- Improve cooling tower performance
- Enhance water resilience
- Support sustainability initiatives
- Maximize the value of existing wastewater treatment infrastructure
The project demonstrates how food and beverage manufacturers can unlock significant value through wastewater reuse while improving both operational and environmental performance.
About ReclaimX™
ReclaimX™ is Apex Water & Process’s advanced wastewater reuse platform designed for food and beverage manufacturers, dairy processors, biofuels facilities, and industrial operations.
By integrating advanced oxidation, ultrafiltration, reverse osmosis, automation, and ongoing optimization, ReclaimX™ helps manufacturers:
- Reduce water consumption
- Lower water and sewer costs
- Recycle wastewater
- Improve sustainability performance
- Recover valuable water resources
Frequently Asked Questions
What are the typical water reuse opportunities at a dairy processing plant?
Common dairy water reuse applications include cooling tower makeup, boiler makeup water, equipment washdown, utility water, and irrigation systems. Most facilities begin with non-product-contact applications, where implementation is simpler and return on investment is often strongest.
What are the key considerations for maximizing a dairy water reuse project?
Successful projects start with understanding wastewater variability and matching treatment technology to the intended reuse application. Pilot testing, effective pretreatment, operational simplicity, and planning for seasonal demand are all critical factors in long-term success.
What are the do's and don'ts when designing a water reclaim system?
Do: Pilot the wastewater stream, design for upset conditions, incorporate effective pretreatment, automate cleaning processes, and plan for future expansion.
Don’t: Design around average wastewater quality, underestimate biological fouling, overlook upstream chemistry changes, or focus solely on minimizing capital cost.
What is unique about Apex ReclaimX™ for wastewater reuse applications?
ReclaimX™ is specifically designed for challenging industrial wastewater streams where conventional reuse systems often struggle. The platform combines advanced oxidation, submerged ultrafiltration, reverse osmosis, Chemically Enhanced Automated Flushing (CEAF), and real-time monitoring to manage wastewater variability, control fouling, and produce reliable reclaimed water. The result is a dependable water reuse solution that lowers freshwater demand, reduces water and sewer costs, and supports long-term sustainability goals.