Foster Farms, Livingston, CA

New 5.0 MGD 4 Stage Biological Nutrient Removal Wastewater Treatment System

Foster Farms owns and operates the world’s largest chicken processing plant in Livingston, California. After several years of negotiations with the City of Livingston regarding sewer rates, Foster Farms elected to design and build their own Wastewater Treatment System. We were selected as the Prime Engineer and designed a Four-Stage Bardenpho Biological Nutrient Removal System to reduce Total Nitrogen to less than 10 mg/l.

Our design saved Foster Farms over 14+ million dollars based on a previous design and estimate by others.

The major treatment system components were as follows:

  • Raw Wastewater Pump Station
  • First Stage Anoxic Reactor #1 with jet aeration and mixing
  • Second Stage Aerobic/Nitrification Reactor #2 with jet aeration and mixing
  • Third Stage Anoxic Reactor #3 with floating mixers
  • Fourth Stage Aerobic Reactor #4 with surface aeration for cooling.
  • Two Final Clarifiers
  • Equipment Building with offices, breakroom, laboratory, chemical feed equipment, and mechanical equipment.
  • Final Effluent Storage Pond for ground water recharge
  • Double Lined Waste Sludge Storage Lagoon
  • Automation and Controls