Defeating FOG Crusts: How a Meat Processor Restored Efficiency with the Landia AeriGator

Across Ohio, numerous meat and food‑processing plants grapple with fats, oils, greases (FOG) and debris clogging their wastewater systems. Even those equipped with pumps marketed as “non‑clog” often find their tanks crusted to the point where no wastewater is visible, and the odor alone can locate a site from a distance.

One leading meat processor faced this exact problem. Their 300,000‑gallon equalization tank had developed a crust so dense that it could be walked on. The plant’s crew had resorted to chemical treatments and a portable pump that blasted the crust four times a year—each visit costing $5,000 and temporarily amplifying odors.

At plant close‑out, the two Dissolved Air Flotation (DAF) units had to lift a surge of solids. Effective fat removal is not only essential for meeting discharge consent and protecting local waterways, but it also generates revenue when the recovered fat is sold to other manufacturers.

Faced with recurring costs, foul odors, and reduced treatment capacity, the facilities manager turned to Smith Environmental for help. Although initially interested in a propeller mixer, Smith’s experienced consultant Paul Matrka quickly realized that a more robust solution was required.

“Never seen a tank so crusted up”

“Over the years we’ve seen very clogged lift stations,” says Matrka. “In my 25+ years, I’ve never seen a tank as crusted as this one.”

Smith Environmental’s portfolio includes chopper pumps equipped with external knives that keep solids out of the casing. When fitted with a venturi nozzle, the pump also serves as an efficient mixer, dispersing air throughout the tank. To demonstrate the capability, Smith proposed a trial of Landia’s AeriGator.

“Bubbles began to emerge and the crust slowly began to break up.”

“We were confident, but the crust was so thick we had to try almost 20 times for more than 15 minutes to lower the AeriGator through the layer,” explains Matrka. “When the scum erupted from the nozzle, it was…disgusting—unless you enjoy thick brown toothpaste! As bubbles appeared, the crust dissolved. The facilities manager was amazed. Installation is simple; an operator can set it up in an afternoon.”

Rather than clearing the entire crust at once—risking a massive slug of fat that could overwhelm the DAF units—Smith Environmental phased the removal. The result is a steadier flow from the equalized tank, eliminating the previous variations that required chemical adjustments and enabling the plant to meet final effluent discharge standards reliably.

“Acquiring this single pump will significantly improve the bottom line,” says Matrka. “The AeriGator pays for itself in just two years.” He adds, “The plant’s odor problem is now a thing of the past. The AeriGator runs 24/7 with no fuss, and the facilities manager is a champion of the product.”

Smith Environmental
go-smith.com (614) 224‑7670
Landia World