Turning Waste into Wealth: How Industrial Wastewater Treatment Fuels Sustainability

This is the initial installment of Valicor's blog series, Water Wisdom: Turning Waste Into Industrial Value. To see all posts in this series, click here.

Could Your Factory’s Wastewater Be A Solution To The Growing Water Scarcity Crisis And A Key To Long-Term Sustainability?

In 2023, Valicor recovered 92% of water from our oily wastewater intake. The recovered water wasn’t just a byproduct – it became a resource. After treatment, this water was returned to surface water recharge systems and for other beneficial reuses. It didn’t simply disappear; it became part of a cycle that supports environmental renewal and sustainability.

Now, imagine what could happen if every industry viewed wastewater the same way. The wastewater your factory produces doesn’t have to be waste – it can be treated to improve water security and boost sustainability, contributing to a nature-positive future. This shift isn’t just an environmental goal; it’s a practical one. Water scarcity is an increasing threat to industries worldwide, driving up costs and operational risks. But what if the wastewater you discard could actually become a valuable asset – reducing your water footprint, cutting costs, and supporting sustainable operations?

The Industrial Water Challenge: Turning Waste into Wealth

Industries across the globe face a twofold challenge: rising water consumption and the need for sustainable operations. Water is essential for countless industrial processes, from cooling and cleaning to chemical reactions. In fact, according to a 2015 U.S. Geological Survey report, a staggering 236 billion gallons of surface water were withdrawn daily in the U.S., with 10% of that supporting industrial processes. While thermoelectric power plants accounted for 56% of this usage, industries represent a significant portion of the demand, underscoring how vital water is to maintaining operations.

But this vast consumption also generates enormous quantities of wastewater, often considered a costly byproduct. This wastewater is typically filled with oils, chemicals, and contaminants, making it unsuitable for reuse—at least at first glance. However, with the right treatment processes, industries can transform wastewater into a valuable resource. Wastewater doesn’t have to be discarded. Instead, it can be treated and reused, cutting water costs, reducing environmental impact, and contributing to long-term water security. For industries, every drop of water that isn’t recovered represents a missed opportunity to operate more efficiently and sustainably.

From Wastewater to Resource: Solutions for a Sustainable Future

Recovering and reusing industrial wastewater isn’t just an environmental imperative – it’s a practical solution for industries grappling with rising water costs and tightening regulations. Take Arizona, for example. Once a looming threat, its water scarcity has now become a reality, leading the state to limit building permits due to water shortages. With dwindling surface water and groundwater supplies, it's crucial to view wastewater through a new lens. By investing in advanced treatment processes, industries can transform their wastewater into a valuable resource, driving sustainability and improving their bottom line. Here’s how:

1. Primary Treatment: Removing Suspended Solids
   The first step in transforming wastewater into reusable water involves primary treatment, where suspended solids, oils, and larger contaminants are removed. Through processes like sedimentation and filtration, this stage helps prepare the water for more advanced treatment techniques. By removing these impurities early on, industries can significantly reduce the strain on their overall wastewater management systems and prepare water for further reuse or disposal.

2. Advanced Treatment: Polishing Water for Reuse
   After primary treatment, more sophisticated processes like membrane filtration, reverse osmosis, or biological treatments come into play. These advanced methods target dissolved solids, heavy metals, and chemical contaminants that can’t be removed through basic treatment. The result is polished water—often over 90% clean—that can be safely reused in industrial processes or for non-potable applications, such as cooling, cleaning, or even irrigation of green spaces within industrial complexes.

3. Water Reuse for Industrial Applications
   The polished water from advanced treatment systems can be recycled back into industrial processes, reducing the need for freshwater extraction. For industries that use large volumes of water—such as manufacturing, textiles, or energy production—this approach offers an opportunity to lower operational costs and safeguard against future water scarcity. Recycled water can be used for cooling systems, cleaning, and even within the production process, depending on the water quality requirements 

Real-World Examples: Industries Turning Wastewater into Wealth

Many industries are already leading the way in transforming wastewater from a liability into an asset. Here are a few examples of how companies are successfully implementing advanced wastewater treatment processes and reaping the rewards:

1. PepsiCo: Water Reuse in Manufacturing
   PepsiCo has long been committed to sustainability, with a strong focus on water stewardship. In several of its manufacturing facilities, the company has implemented advanced wastewater treatment systems that recover and reuse up to 80% of the water used in production processes . By doing so, PepsiCo reduces its freshwater demand, contributing to water conservation efforts and lowering operational costs. In areas prone to water scarcity, this reuse is critical to maintain operations without depleting local water supplies.
   
   
2. Nestlé’s Zero Water Factory in Mexico
   Nestlé took a significant step toward water sustainability with its dairy factory in Jalisco, Mexico, where the company operates one of the world’s first “zero water” plants . By recycling the water extracted from milk during production, Nestlé reduces its reliance on external water sources. This innovative approach enables the factory to operate without consuming additional freshwater, turning the wastewater from its own processes into a vital resource.
   
   
3. Ford Motor Company: Treating Wastewater for Industrial Reuse
   Ford has implemented cutting-edge wastewater treatment technologies at its manufacturing plants worldwide. At its assembly plant in Chennai, India, Ford captures and treats almost 100 percent of industrial wastewater , recycling it for non-potable uses such as cooling systems, landscaping, and car washing. This effort has significantly reduced the plant's water consumption, allowing Ford to operate more sustainably in a region where water scarcity is a growing concern.

The Future of Industry is Water-Wise

The examples we’ve explored demonstrate that wastewater is not just a byproduct to be managed – it’s a resource that, when properly treated, can fuel sustainable growth. In today’s world, where water scarcity is an increasing concern, industries that embrace wastewater reuse are not only future-proofing their operations but also leading the charge toward a more sustainable future.

With the right infrastructure in place – such as advanced treatment systems and centralized pretreatment facilities – industries can recover water, reduce costs, and lessen their environmental impact. This is not just about meeting regulatory requirements; it’s about creating a business model that thrives on efficiency and resourcefulness.

As the world shifts toward greener practices, those who invest in sustainable water management today will be the ones who reap the rewards tomorrow. Industrial wastewater is a valuable asset, and companies that harness it will help build a future that’s both nature-positive and business-savvy. The question is: will your company be part of this transformation?

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