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Fortune 100 Manufacturing Plant Utilizes Wastewater Treatment Plant to Bring Highly Complex Wastewater into Industry Compliance

Project Overview

When a Fortune 100 manufacturing facility was challenged to bring their complex wastewater up to industry compliance standards, SAMCO was selected to design, build, own, operate, and maintain (DBOOM) a major wastewater treatment plant (WWTP) at the company’s primary location in the Northeast.

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DBOOM WWTP at client’s main manufacturing location to treat highly complex and variable wastewater per industry compliance standards, including:

  • Oil and grease < 60 ppm
  • Total suspended solids (TSS) < 100 ppm
  • Zinc < 1.5 ppm
  • Chromium < 0.5 ppm
  • Phenol < 0.8

Scope of Service

The client worked with SAMCO to develop an effective solution that comprised a treatability/pilot study, detailed design/engineering, system fabrication/integration, field installation, commission/ startup, and ongoing operation and maintenance (O&M)


  • Highly complex contaminants and varied flow
  • Plant expansion/increased wastewater volume
  • Stringent discharge limitations
  • Reduce O&M cost


Trucked in from multiple locations, the client’s contaminated waste resulted from press pit, zyglo dye, fume exhaust, and high pH etching manufacturing procedures, among others. SAMCO efficiently utilized source-segregation strategies to reduce contaminant loads, chemical feed, and sludge waste. Dissolved air flotation was used in lieu of a clarifier to remove suspended solids, reduce chemical feed and sludge waste, handle the added expansion load, and provide the client with a less-than- one-year payback. A prepackaged system and modular design enabled quick and easy installation with guaranteed performance and future add-on capabilities, and SAMCO also included programmable logic controllers (PLC) that automate monitoring of flow, temperature, pressure, and resistivity.


Project deliverables and equipment included:

  • Equalization tanks
  • Influent pumps
  • Chemical feeds
  • Reaction tanks unit
  • Oil/water separator
  • Dissolved air flotation
  • Inclined plate clarifier
  • Sludge handling/filter press
  • Multimedia and activated carbon filters
  • Platform/stairs
  • PLC controls