The water reuse and regeneration project within bottling lines and brewery processes introduces an integrated solution for industrial water efficiency, with special emphasis on the treatment of complex effluents generated by the brewing industry. Unlike conventional municipal wastewater, brewery effluents exhibit high organic load, elevated concentrations of sugars, nitrogenous compounds, yeast residues, and cleaning agents such as alkalis and peracetic acids.
To address this challenge, a dedicated treatment line was developed to manage the variable and high-strength brewery effluent, capable of processing 1,920 m³/day through an advanced technological sequence. This line includes an anoxic reactor, aerobic reactor, membrane bioreactor (MBR), disinfection tank, activated carbon filter, and reverse osmosis (RO). The result is a daily production of 1,440 m³ of regenerated water, meeting A+ potable quality standards in strict compliance with Royal Decree 1085/2024 for safe reuse in industrial applications.
This solution not only improves the plant’s environmental performance but also avoids more than 700,000 m³/year of freshwater abstraction while generating an estimated 525,000 m³/year of reused water. It represents a tangible enhancement in water circularity within the brewing process, reducing pressure on conventional sources and strengthening resilience to water scarcity scenarios.
The conventional use of potable water in industrial processes such as bottling and especially brewing entails significant volumes of abstraction, with traditionally low reuse rates. This is further aggravated in coastal regions with high industrial density and water stress, where some of Europe’s largest brewery facilities are located. In such locations, continuous large-scale production demands constant flows of blue water for brewing, cleaning, cooling, and auxiliary services.
Moreover, brewery effluent contains high levels of organic matter, including residual sugars, proteins, yeast, and cleaning chemicals—requiring advanced treatment technologies beyond those used in standard industrial plants. Failure to regenerate this water represents a significant operational and energy loss, as it could be reused in non-potable process steps such as bottle washing, equipment cleaning, or cooling towers. Continuing inefficient water-intensive practices also presents increasing regulatory and reputational risks, especially in European contexts with strict environmental targets, decarbonization goals, and net positive water impact ambitions
The project deploys an advanced treatment system that transforms treated brewery effluent into high-quality water suitable for internal non-potable uses such as bottle washing. This is particularly relevant in the brewing context, where bottle washing is one of the most water-intensive steps in the production chain. Stringent hygiene and safety standards require a reliable supply of clean, safe, and high-quality water to prevent cross-contamination or impact on the final product.
In coastal locations such as the Barcelona metropolitan area—where freshwater sources are increasingly stressed and aquifer salinization is an escalating threat—reducing blue water abstraction becomes a strategic imperative. Regenerated water availability for non-potable tasks such as bottle washing not only optimizes resources but also helps prevent overexploitation of vulnerable hydrological systems. Replacing potable water for such uses improves urban and industrial water resilience.
Thanks to advanced regeneration, a significant portion of the treated water can be redirected to the returnable bottle washing circuit, closing a critical loop within the plant and significantly reducing dependence on external supply. The technological configuration includes combined biological treatment (anoxic-aerobic), membrane filtration (MBR), controlled disinfection, activated carbon filtration, and reverse osmosis. This sequence ensures the removal of both organic and inorganic contaminants, as well as microbiological quality suitable for sensitive industrial uses.
The entire system is designed for continuous operation, with online monitoring of critical parameters and full traceability, facilitating seamless integration into high-capacity brewery operations with strict hygiene controls. It meets both regulatory compliance requirements and the sector’s sustainability commitments.
The solution is structured around a robust technological train tailored to the particularities of brewery effluent, which has a high organic load and variable composition. The treatment train includes anoxic and aerobic bioreactors for the efficient breakdown of nitrogen compounds and complex organics. The water is then routed through a membrane bioreactor (MBR) system, which combines biological treatment with advanced physical separation, ensuring high-quality effluent.
The water then undergoes disinfection in a sealed contact tank, followed by tertiary polishing using activated carbon filtration to remove trace organics and micropollutants. Finally, the process is completed with a reverse osmosis (RO) stage, ensuring A+ quality water compliant with Royal Decree 1085/2024—safe for sensitive applications such as returnable bottle washing.
The system includes a state-of-the-art automation architecture with integrated PLCs and SCADA, inline sensors for flow, conductivity, turbidity, residual chlorine, and microbiological parameters. This enables continuous operation with full traceability, ensuring not only compliance but also resilient and efficient water management. Moreover, the facility has been designed for modularity, enabling replication and scaling across other brewery plants in the group or the sector.
The project began with a thorough characterization of the effluent generated at the brewery, accounting for its variable composition and high organic load. A customized water treatment system was designed to integrate advanced bioprocesses with physical-chemical stages, meeting the requirements of Royal Decree 1085/2024.
The system treats secondary effluent from brewing operations and auxiliary services. It passes first through a two-stage biological treatment: an anoxic reactor supporting denitrification, followed by an aerobic reactor for further degradation of biodegradable organic matter. The water then flows through an MBR system, which provides effective removal of solids and pathogens, improving process stability and effluent quality.
The filtered water is stored in a contact tank for controlled disinfection, then undergoes polishing via activated carbon filters to eliminate trace organics and improve taste, odor, and chemical safety. The final stage is high-efficiency reverse osmosis, delivering A+ quality water for demanding industrial uses.
The regenerated water, averaging 1,440 m³/day, is stored in internal distribution tanks and reused in processes such as bottle washing, equipment cleaning, and cooling towers. This recirculation avoids over 700,000 m³ of potable water abstraction annually, translating into 525,000 m³/year of reused water within the same facility.
This operational model is fully aligned with VWBA 2.0 principles and metrics. It includes a documented baseline, demonstrated additionality, and traceability through continuous monitoring systems. It is thus eligible for reporting under CDP Water, ESRS E3, Science-Based Targets for Water, and certification platforms like Aqua Positive, ensuring a credible and permanent accounting of water benefits aligned with the SDGs.
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