King’s Hawaiian Bakery – Alpha System

At the Flowery Branch location, King’s Hawaiian constructed a second facility for the manufacture of pretzels.    The existing pretreatment system for the bakery was insufficient for the additional loading, and it was inconveniently located with respect to the new manufacturing facility.  Therefore, a second wastewater pretreatment system was constructed to handle the wastewater from the pretzel lines.

• Pretreatment of fairly high BOD concentrations
• Area allocated for wastewater system was a small knoll area adjacent to the property line
• High pH wastewater from alkali baths
• Initially, used one dissolved air flotation (DAF) unit for both primary and secondary functions
• System designed for expansion to two DAF units, which doubled the flow capacity

The pretreatment system is comprised of the following major components:

• Rotary screen
• EQ Tank with aeration
• Primary/secondary DAF unit with Reactor and Floc Tanks
• Bioreactor with aeration
• Two Sludge Tanks with aeration
• Calamity Tank
• Expanded to secondary DAF unit with Floc Tank
• Effluent monitoring

The wastewater pretreatment system at Alpha operated in the primary/secondary mode using one DAF for two years before the system expansion was necessary.  The system was initially designed with the expansion in mind so that minimal construction/installation for separate primary and secondary operations was required.