This project proposes the valorization and reuse of condensate water generated during the thermal concentration of whey at the plant located in Rafaela, Santa Fe Province. This secondary stream, commonly referred to as “cow water,” is a high-volume byproduct with low contaminant load, making it an excellent source of reusable water within the industrial process.
Taking advantage of the plant’s existing high level of automation and technical development, a modular physical system will be implemented to treat this stream through advanced separation, thermal stabilization, advanced oxidation, and non-chemical disinfection. This technology, inspired by electromagnetic separation and selective oxidation systems, guarantees the safety of the treated water and its reintegration for non-potable industrial uses such as CIP cleaning, equipment pre-washing, and cooling towers.
The solution is structured according to the Volumetric Water Benefit Accounting (VWBA 2.0) framework by reducing blue water abstraction from external sources, and the Water Quality Benefit Accounting (WQBA) approach by avoiding additional discharges and reducing loading on the effluent treatment system. The project reinforces operational circularity, optimizes water efficiency, and contributes to regional sustainability within the Salado River Basin.
Despite the plant’s modern infrastructure and strong technical capacity, whey condensate, generated mainly during whey evaporation, is not currently routed to a dedicated reuse circuit within the industrial process. This stream constitutes a significant portion of the total water flow, characterized by low dissolved solids and low organic load, yet contains traces of volatile compounds that require specific physical conditioning to ensure safety.
The main cause of this omission lies not in technological limitations, but in the absence of a water valorization strategy that prioritizes internal circuit closure and operational efficiency. Water management at the plant has historically focused on effluent treatment and disposal, overlooking the potential of these secondary streams as reusable sources. As a result, whey condensate is systematically discharged into the treatment system, unnecessarily increasing its hydraulic load and reducing overall efficiency.
Additionally, the failure to recover this flow leads to continued abstraction of freshwater for tasks such as CIP cleaning, tray washing, or boiler feed, which increases the operation’s blue water footprint. Although accepted operationally, this practice represents a missed technical and environmental opportunity, particularly considering the water stress affecting the Salado River Basin and the growing pressure to optimize water use.
The project includes the implementation of a dedicated treatment line for whey condensate, designed with an advanced physical-mechanical approach that avoids the use of chemicals and adapts to the intermittent and variable flows typical of this stream. The system incorporates a multi-layer filtration stage to remove suspended particles and organic solids, followed by a thermal stabilization unit to homogenize temperature and remove volatile compounds through controlled thermal conditioning.
Next, an advanced oxidation process (AOP) reactor is used to degrade residual organic molecules using controlled oxidative species (such as hydroxyl radicals), without forming toxic byproducts. The final stage involves high-intensity UV disinfection, ensuring microbiological safety before storage and recirculation of the treated water.
This solution, modular and energy-efficient in design, is inspired by selective electromagnetic separation technologies, continuous flow operation, and automatic self-cleaning protocols, allowing seamless integration with the plant’s existing SCADA systems. With a recovery efficiency of up to 90%, the treated water exhibits stable conductivity, low microbial load, and absence of critical compounds, complying with internal standards for safe reuse in non-potable applications such as CIP, cooling towers, and equipment washing.
The implementation of the whey condensate reuse system at the plant is structured in four sequential phases, each with specific technical objectives, key activities, and associated control parameters:
Technologies or actions applied: Modular system for treating whey condensate, based on advanced physical separation, thermal stabilization, and non-chemical oxidation. A compact, scalable, and energy-efficient solution tailored for high-load industrial environments. Adaptable to variable flows and compliant with internal sanitary standards.
Technical Diagnosis and Design: This phase includes exhaustive mapping of whey condensate generation points within the plant, identifying intermittent flows and operational conditions for each line. Representative samples are taken for physico-chemical (conductivity, TDS, temperature, volatile compounds) and microbiological (total coliforms, mesophiles) analysis. Based on these results, the treatment system is dimensioned and quality parameters defined according to intended internal uses (CIP, cooling, auxiliary services).
Installation of the Treatment Line: This stage involves installing the technology modules in series. Multi-layer prefiltration removes particles above 50 microns, followed by a thermal stabilization unit that maintains constant temperatures, eliminates volatiles, and avoids thermal shocks in subsequent stages. The AOP reactor is calibrated based on the expected organic load to perform advanced oxidation without generating toxic byproducts. A dual-pass UV disinfection unit ensures the microbiological safety of the treated effluent, validated through log-reduction testing.
Operational Integration: Once stabilized, the treatment system is connected hydraulically and electronically to the plant’s internal circuits. Treated water is directed to intermediate tanks and distributed based on process needs. The system is integrated into the SCADA platform, allowing real-time monitoring of flow, pressure, and temperature, with alarms for deviations. Contingency protocols are also configured for automatic diversion if microbiological or conductivity parameters deviate.
Monitoring and Maintenance: The system includes a continuous monitoring plan with in-line sensors measuring conductivity, turbidity, TDS, and temperature at key points. Composite samples are analyzed weekly to validate water quality, and internal audits verify energy consumption (kWh/m³), contaminant removal efficiency, and system integrity. Automatic cleaning and quarterly predictive and corrective maintenance cycles are included.
Controls and measurements by phase:
Monitoring Plan:
Partnerships and implementing actors:
This project aims to transform the internal water management of the plant by recovering, treating, and reusing condensate water generated during the whey evaporation process. This stream, commonly referred to as “cow water,” constitutes a technically recoverable fraction of the total water flow, characterized by its low dissolved solids content and minimal microbiological load. Despite its favorable characteristics, its potential has historically been underutilized due to the lack of specific water valorization strategies.
Through a comprehensive technical and operational analysis, it was determined that this stream can be treated using state-of-the-art technologies based on advanced physical processes, without requiring chemical inputs or generating secondary waste. These technologies, such as multi-layer filtration, thermal stabilization, advanced oxidation processes (AOP), and dual-pass UV disinfection, effectively remove particles, eliminate volatile compounds, and ensure the microbiological safety of the treated water. The resulting water quality allows for safe reuse in non-potable applications such as CIP cleaning, tray washing, indirect cooling, and thermal service supply, thus replacing potable water in those uses.
The project implementation is structured into four successive technical stages. First, the system is diagnosed and designed through detailed characterization of the condensate’s flow, composition, and destination. Second, a modular and scalable treatment line is installed and adapted to the plant’s existing infrastructure. The third stage integrates the system into daily operations, linking it with SCADA and internal distribution systems. Finally, a predictive monitoring and maintenance plan is established, including in-line sensors, microbiological quality control, and energy efficiency assessment.
Methodologically, the project is structured under the Volumetric Water Benefit Accounting (VWBA 2.0) framework, by generating measurable savings of blue water, and the Water Quality Benefit Accounting (WQBA) approach, by reducing the load on effluent treatment systems. This dual contribution—both in demand reduction and discharge quality improvement, makes it possible to quantify and validate the project’s positive water impact. Furthermore, the initiative aligns with the Sustainable Development Goals (SDGs), by integrating innovation, industrial sustainability, resource efficiency, and strategic partnerships for transforming the plant’s water management model.
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