Sara Lee Case Study

The Situation
Sara Lee operates a production facility in Florence, AL that operates 6 pork sausage cookers. The pork
sausage cookers previously used electrostatic precipitators (ESPs) to treat the grease and smoke-laden
exhaust. Two ESPs were handling all six cooker lines. The ESPs were aging and losing effectiveness and
ongoing maintenance and operating costs were high. Filter technology had proven to be ineffective,
requiring frequent cleanings and were unable to consistently remove the finer particulates.
The exhaust streams from the cookers are saturated with moisture and the pollutant load is mainly pork
grease. Existing exhaust rates average approximately 4,600 ACFM for each of the various cookers.
Solution requested
Sara Lee requested a solution to replace the existing ESPs, starting with a test installation on one of the
production lines. The requirements included:
Exceed regulatory requirements for the largest potential waste gas stream, ~7,000 ACFM
containing 2.5 lbs/hr of grease and smoke laden particulates. The local regulatory requirements
tie emission limits to production rates and is expressed by the formula, E=3.59 *P(0.62), where E
is emissions (lbs/hr) and P is production shrinkage (tons/hr).
Provide independent pollution abatement control for each cooker, yielding increased
production and maintenance flexibility.
Removal of difficult sub-micron particulates for a cleaner exhaust.
Consistently maintain performance/compliance through long duration and continuous
production demands.
Low maintenance and ease of operation for the equipment.
Economic capital outlay for the equipment and low operating and maintenance costs.
Solution Recommended
Pollution Systems engineers recommended Venturi Scrubber technology for this difficult application,
and specifically Venturi Scrubber Model #VS-5. Historically, this technology has been successfully
utilized to reduce particulate matter emissions for both batch and continuous process operations for the
meat smoking / processing industry. These scrubbers have the ability to remove particulates less than 1
micron in size and at high removal efficiencies. In addition, the VS-5 Venturi Scrubber was an attractive
solution when evaluating upfront investment and ongoing operating expenses compared to other
technologies.
With the installation of multiple venturi scrubbers, they operated independently for each production
cooker, providing flexibility during production and maintenance cycles.
Product Information
Pollution System Solutions Model VS-5 Venturi Scrubber is a self-contained, skid-mounted particulate
scrubbing system. Features include:
Stainless steel construction, using 304stainless steel for all air-stream-contacted surfaces and
structural components.
Removable mist eliminator pads constructed of 304 stainless steel
Self-contained manifold system with clean-in-place (CIP) nozzles
System fan
Internal Sump and Recycle pump

Instrumentation and controls, including a NEMA 4 control panel
Exhaust stack
The scrubber operates by drawing the grease and smoke-laden exhaust waste gas through the scrubber
using the scrubber fan. Water from the recirculation tank is introduced into the venturi throat, causing
fine water droplets to be formed. The grease and particulates are then collected on the droplets and
carried to the lower portion of the scrubber where the air velocity slows down, allowing the particleladen droplets to fall into the recirculation sump. The treated waste gas stream then passes through the
mist eliminator prior to discharge to atmosphere.
A portion of the scrubbing fluid is blown down to wastewater discharge and fresh make-up water is
added to the scrubber. This reduces waste buildup, decreases the frequency of cleaning, minimizes
maintenance costs, and increases operational efficiency.
Pollution Systems Services

Pollution Systems reviewed the process application and provided engineered drawings and
specifications to Sara Lees evaluation team. An initial installation of one scrubber was approved to test
the effectiveness of the solution. After the scrubber was manufactured and shipped to the Florence, AL
plant, Pollution Systems experienced field technicians inspected the unit, reviewed the installation and
provided commissioning. Training was also provided to Sara Lees staff to operate and maintain the
scrubber.
Delivery, installation, and start-up were completed within the projected timeline and budget.
Results
The VS-5 Venturi Scrubber provided the expected performance. Emissions testing and operational
experience have proven the scrubber to be effective and with low maintenance. It has outperformed
the existing ESPs and has provided Sara Lee with effective emissions control for current and future
production volumes. Sara Lee has subsequently purchased multiple additional Venturi Scrubbers for its
pork sausage cookers.

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The Situation

Internal Sump and Recycle pump

Pollution Systems Services

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