Wastewater Treatment and Water Recycling for New Production Sites: Proven Concept for Safe Discharge and Stable Operations

Wastewater Treatment and Water Recycling for New Production Sites: Proven Concept for Safe Discharge and Stable Operations

At new production sites, wastewater volumes and compositions are often difficult to predict. For a cosmetics manufacturer in Germany, EnviroChemie implemented a tailor-made wastewater treatment plant with integrated water recycling for reuse. The system is designed for a capacity of 60 m³ of wastewater per day and ensures reliable compliance with strict discharge limits while reducing freshwater consumption.

What we did

EnviroChemie planned and installed a customized wastewater treatment and water recycling system based on Flomar® flotation, aerobic Biomar® OKB, and downstream water recovery using ultrafiltration and softening. The project is part of a long-standing partnership with the customer. In addition, EnviroChemie operates the plant, ensuring consistently stable and reliable system performance.

Task
Solution
Benefits

Task

At the new production site, wastewater from cleaning processes was generated with highly variable composition. In particular, residual products such as silicone oils from deodorant and hairspray production posed an additional challenge. At the same time, strict limits for organic load as well as a maximum discharge load of 60 kg COD per day had to be reliably met. Another key requirement was to conserve water resources and enable partial reuse of the treated wastewater within the production process.

Solution

The wastewater is first pre-treated using dissolved air flotation (Flomar®) to effectively remove poorly biodegradable components. In the subsequent biological treatment stage (Biomar® OKB), the remaining organic load is further reduced. The treated wastewater is then polished via ultrafiltration and softening to enable reuse. A portion of the treated water is returned directly to the production process, while the remaining volume is safely discharged into the sewer system in full compliance with regulations.

Benefits

The system combines reliable wastewater treatment with targeted water reuse, sustainably reducing freshwater demand at the site. The multi-stage treatment process ensures high water quality, enabling stable reuse within production. At the same time, the system guarantees full compliance with all discharge limits. Integrated plant operation by EnviroChemie ensures long-term reliability and reduces both technical and organizational workload for the customer—resulting in a cost-effective and sustainable solution for cosmetics production.

Contact

General contact

General contact

+49 6154 6998 100